Note: Descriptions are shown in the official language in which they were submitted.
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APPARATUS AND METHOD FOR
FRAME AND BRICK CONSTRUCTIONS
CROSS REFERENCE TO RELATED APPLICATIONS
100011 This application claims the benefit of (1) provisional patent
application U.S. Serial
No. 61/223,745 filed July 8, 2009, by the present inventor and (2) provisional
patent
application U.S. Serial No. 61/231,477 filed August 5, 2009, by the present
inventor.
TECHNICAL FIELD OF THE INVENTION
[0002] This invention relates generally to apparatus and methods for
constructing and
installing bricks, such as refractory bricks, in frames, staves and/or coolers
in blast furnaces or
other metallurgical furnaces. Related fields include systems and methods for
cooling blast
furnaces and other metallurgical furnaces. Related fields include cooling
plates and cooling
staves.
BACKGROUND - FIELD OF THE DISCLOSURE
100031 Conventional designs and constructions for cooling refractory bricks in
blast furnaces
and other metallurgical furnaces include cooling staves. Conventional copper
cooling staves
are generally planar, rectangularly shaped and arranged within a furnace
substantially parallel
or as parallel as possible, given the shapes of the staves and/or the interior
of the furnace, to
the metal shell of the furnace. The cooling staves typically cover a high
percentage of the
inner surface of the metal shell of the furnace. Refractory lining, such as
refractory bricks,
may be disposed in, on or around the surface of the stave, such as, for
example, bricks
disposed within slots or channels defined by the stave. Staves also have
cavities that provide
passages or house internal piping. Such passages or piping are connected to
one or more
external pipes that extend from the furnace shell side of the stave and
penetrate the metal shell
of the furnace. Coolant, such as, for example, water at an elevated pressure
is pumped through
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the pipes and passages in order to cool the stave. The cooled stave thus cools
the refractory
bricks disposed within slots or channels defined by the stave.
[0004] Current stave or cooling panel brick designs typically are installed in
grooves or
channels in the cooler before installing the cooling stave/panel in the
furnace. Further, many
conventional refractory bricks are designed to be installed in a flat stave or
cooler. When
using flat or curved staves/coolers with pre-installed bricks, the staves are
installed in the
furnace and have a ram gap in between each pair of adjacent staves to allow
for construction
deviation. These ram gaps are then filled with refractory material to close
the gap between the
stave/brick constructions on the sides of the gap. This refractory filled ram
gap typically is a
weak point in a furnace lining comprising conventional stave/brick
constructions. During
furnace operation, the ram gap often erodes prematurely and furnace gases
track between the
staves. Moreover, such conventional stave/brick constructions leave brick
edges protruding
into the furnace which are exposed to matter and other debris falling through
the furnace.
Such protruding brick edges tend to wear out more frequently than non-
protruding edges,
leading to broken or crumbled bricks that may fall through the furnace causing
further
damage to the furnace lining. Such broken bricks also expose the stave thereby
causing it to
be damaged or worn out prematurely.
[0005] Current stave or cooling panel bricks are typically either installed in
straight grooves
employed as the main method of attachment to keep the bricks in the cooler or
tapered to
force bricks which are not locked in grooves in the stave to push against the
cooler when the
bricks are heated during furnace operation.
[0006] Also, in recent years, it has been a common practice to install staves
without
refractory in front of them and try to form a skull layer to protect and
insulate the stave in a
blast furnace. This process related skull is generated and lost repeatedly in
service and
actually changes furnace performance. Skulls can only be formed in the
cohesive zones of the
furnace. Therefore, this skull approach is not effective if the cohesive zone
is incorrectly
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determined. Additionally, the cohesive zone of the furnace changes depending
on charge
material and the skull adhesion is lost in sections of the furnace at
different times. This
results in non-unifoini temperatures throughout the staves and furnace.
However, an
improved brick refractory lining protects the stave regardless of adhesion and
would be
preferable to such skull insulating process, even through in some cases it may
still be
desirable to form the skull to protect the improved refractory.
[0007] Current locked-in brick designs, such as dovetailed bricks in
complementary-shaped
stave channels, are relatively thin throughout their vertical thickness. Such
thin-necked bricks
are susceptible to cracking at the thin neck portion thereby creating brick
fragments and
pieces falling into the furnace which may hit and damage other bricks and
staves of the
furnace lining.
[0008] Many older stave designs which incorporate bricks in front of the stave
employ
multiple rows or layers of bricks in front of the stave. Such constructions
contain joints
which further prevent effective cooling of the bricks farthest from the stave.
[0009] As listed above, many shortcomings are associated with known stave and
refractory
brick constructions.
[0010] Accordingly, it would be desirable to provide a stave/brick
construction in which the
refractory bricks may be installed in a flat or curved stave or cooler, before
or after the stave
cooler is installed in a furnace. Additionally, in the event of a reworking or
rebuilding of the
stave/brick construction in the furnace, the refractory bricks of the present
invention can be
replaced or re-installed in-whole or in-part, without removing the stave or
cooler from the
furnace.
[0011] In addition, it would be desirable to provide a stave/brick
construction which provides
a continuous lining around the interior circumference of the furnace that
eliminates ram gaps
between the bricks of adjacent staves and thereby increases the integrity and
life of the
furnace lining.
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[0012] Further, it would be desirable to provide a stave/brick construction
ideal for use in
blast furnaces in which no brick edges are exposed or protrude into the
furnace to increase the
life and integrity of the furnace lining.
[0013] In addition, it would be desirable to provide a stave/refractory brick
construction in
which the refractory bricks can be installed in a stave or cooler that is
tilted on an angle with
the bricks staying in the grooves in such stave or cooler and in which the
bricks may be
inserted and/or removed from the front face of the stave before and/or after
the stave is
installed in the furnace.
[0014] Furthermore, it would be desirable to provide a stave/refractory brick
construction in
which the refractory bricks are doubly locked into the channels in the stave
(1) by
complementary surfaces of the bricks and stave channels that are engaged by
inserting a
portion of each brick into a channel or groove in the stave and simultaneously
or thereafter
rotating each brick on an axis substantially parallel to a plane of the stave
and/or (b) such that
the bottom of the brick rotates in a direction towards or substantively
towards the stave in
order to engage such complementary surfaces of the channel and brick in order
to secure or
lock the brick into the channel chamber and prevent it from moving linearly
out of the
channel or groove through an opening in the front face of the stave and (2) by
oblique or
tapered sections of the bricks that expand when heated during furnace
operation, and push
against the stave or cooler to maintain an effective bond therewith thereby
providing highly
effective cooling of the bricks, while also holding in place any bricks that
might crack or
break.
[0015] Moreover, it would be desirable to provide a stave/refractory brick
construction in
which the stave surface temperature is uniform and which allows for more
consistent furnace
operation with less loss of heat to thereby reduce stresses on the furnace and
staves and
increase the life of both.
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[0016] Further yet, it would be desirable to provide a stave/refractory brick
construction
utilizing bricks having an increased vertical or neck thickness to increase
strength and make
the bricks less susceptible to cracking while also allowing the bricks to be
installed faster,
with the additional weight of each brick helping to keep it in place and less
susceptible to
failure.
[0017] Additionally, it would be desirable to provide an improved
stave/refractory brick
construction having a single layer of bricks in tight contact with the stave
to eliminate thermal
barriers associated with conventional stave/brick constructions having
multiple layers and/or
multiple mortar joints.
[0018] Further still, it would be desirable to provide an improved
stave/refractory brick
construction in which the refractory bricks are made of differing shapes
and/or materials
depending upon the type of furnace and/or the installation location within the
furnace.
[0019] In addition, it would be desirable to provide an improved frame/brick
construction for
any application where it would be advantageous to be able to (1) brick, re-
brick and/or repair
the frame/brick construction after the frame has been installed and/or (2) to
employ the double
brick locking features of the present invention for elevated temperature
applications.
[0020] These and other advantages of the invention will be appreciated by
reference to the
detailed description of the preferred embodiment(s) that follow.
BRIEF SUMMARY OF THE INVENTION
[0021] In a first aspect, the present invention comprises a stave/brick
construction,
comprising: a stave having a plurality of ribs and a plurality of channels,
wherein a front face
of the stave defmes a first opening into each of the channels; and a plurality
of bricks wherein
each brick is insertable into one of the plurality of channels via its first
opening to a position,
upon rotation of the brick, partially disposed in the one channel such that
one or more
portions of the brick at least partially engage one or more surfaces of the
one channel and/or
of a first rib of the plurality of ribs whereby the brick is locked against
removal from the one
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channel through its first opening via linear movement without first being
rotated. Preferably,
the stave may define one or more side openings into each of the channels.
Also, the one or
more portions of the brick comprises a nose at least partially disposed in a
first section of the
one channel, which is preferably complementary to the nose. In addition,
rotation of the brick
comprises a bottom of the brick moving in a direction towards the stave.
[0022] In accordance with yet another aspect of the stave/brick construction,
a first rib
surface of the first rib preferably is complementary to a groove defined by a
top of the brick
and the first rib surface is at least partially disposed in the groove.
[0023] In accordance with yet a further aspect of the stave/brick
construction, each of the
plurality of bricks can be removed from its respective channel via rotation of
each brick
comprising a bottom of each brick moving in a direction away from the stave.
[0024] In yet a further aspect of the stave/brick construction, the stave is
preferably either
substantially flat or curved with respect to one or both of a horizontal axis
and a vertical axis
of the stave.
[0025] In yet an additional aspect of the stave/brick construction, the stave
houses a plurality
of pipes.
[0026] In yet a further aspect of the stave/brick construction, preferably the
plurality of
bricks at least partially disposed in the plurality of channels form a
plurality of stacked,
substantially horizontal rows of bricks protruding from the front face of the
stave, where the
plurality of bricks comprise exposed faces that preferably define a flat
surface or uneven
surface.
[0027] In accordance with yet a further aspect of the stave/brick
construction, one of the
bricks cannot be pulled and/or rotated out of the first opening of its
respective channel when
another brick is disposed in the row above and partially or completely covers
the one brick.
[0028] In accordance with yet another aspect of the present invention, the
stave/brick
construction comprises a plurality of staves standing side-by-side with gaps
between adjacent
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staves; wherein each stave has a plurality of ribs, a plurality of channels,
and a plurality of
substantially horizontal rows of bricks disposed in the plurality of channels.
Preferably, the
plurality of substantially horizontal rows of bricks disposed in the plurality
of channels
covers, in-whole or in-part, the gaps between adjacent staves. Also, the
staves stand
substantially vertically or at an angle other than about 90 degrees.
[0029] In yet a further aspect of the stave/brick construction, each of the
plurality of bricks
further defines a seat wherein the seat is at least partially disposed in a
second section of the
one channel and preferably the second section is complementary to the seat.
[0030] In yet an additional aspect of the stave/brick construction, each of
the plurality of
bricks comprises an oblique top section and an oblique bottom section, wherein
each of the
oblique top and bottom sections protrude from the face of the stave and
preferably the oblique
top and bottom sections of each brick are substantially parallel to each
other.
[0031] In accordance with yet another aspect of the stave/brick construction
of the present
invention, the plurality of bricks at least partially disposed in the
plurality of channels form a
plurality of stacked, substantially horizontal rows of bricks protruding from
the front face of
the stave; and wherein the oblique top section of one brick is disposed
substantially near,
adjacent to, in partial contact with or in complete contact with the oblique
bottom section of
another brick immediately above the one brick.
[0032] In yet an additional aspect, the stave/brick construction of the
present invention
further comprises means for operatively connecting a thermocouple to the
stave.
[0033] In another aspect, the present invention comprises a frame/brick
construction,
comprising: a frame having a plurality of ribs and a plurality of channels,
wherein a front face
of the frame defmes a first opening into each of the channels; and a plurality
of bricks
wherein each brick is insertable into one of the plurality of channels via its
first opening to a
position, upon rotation of the brick, partially disposed in the one channel
such that one or
more portions of the brick at least partially engage one or more surfaces of
the one channel
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and/or of a first rib of the plurality of ribs whereby the brick is locked
against removal from
the one channel through its first opening via linear movement without first
being rotated.
Preferably, the frame may define one or more side openings into each of the
channels. Also,
the one or more portions of the brick comprises a nose at least partially
disposed in a first
section of the one channel, which is preferably complementary to the nose. In
addition,
rotation of the brick comprises a bottom of the brick moving in a direction
towards the frame.
[0034] In accordance with yet another aspect of the frame/brick construction,
a first rib
surface of the first rib preferably is complementary to a groove defined by a
top of the brick
and the first rib surface is at least partially disposed in the groove.
[0035] In accordance with yet a further aspect of the frame/brick
construction, each of the
plurality of bricks can be removed from its respective channel via rotation of
each brick
comprising a bottom of each brick moving in a direction away from the frame.
[0036] In yet a further aspect of the frame/brick construction, the frame is
preferably either
substantially flat or curved with respect to one or both of a horizontal axis
and a vertical axis
of the frame.
[0037] In yet a further aspect of the frame/brick construction, preferably the
plurality of
bricks at least partially disposed in the plurality of channels form a
plurality of stacked,
substantially horizontal rows of bricks protruding from the front face of the
frame, where the
plurality of bricks comprise exposed faces that preferably define a flat
surface or uneven
surface.
[0038] In accordance with yet a further aspect of the frame/brick
construction, one of the
bricks cannot be pulled and/or rotated out of the first opening of its
respective channel when
another brick is disposed in the row above and partially or completely covers
the one brick.
[0039] In accordance with yet another aspect of the present invention, the
frame/brick
construction comprises a plurality of frames standing side-by-side with gaps
between adjacent
frames; wherein each frame has a plurality of ribs, a plurality of channels,
and a plurality of
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substantially horizontal rows of bricks disposed in the plurality of channels.
Preferably, the
plurality of substantially horizontal rows of bricks disposed in the plurality
of channels
covers, in-whole or in-part, the gaps between adjacent frames. Also, the
frames stand
substantially vertically or at an angle other than about 90 degrees.
[0040] In yet a further aspect of the frame/brick construction, each of the
plurality of bricks
further defines a seat wherein the seat is at least partially disposed in a
second section of the
one channel and preferably the second section is complementary to the seat.
[0041] In yet an additional aspect of the frame/brick construction, each of
the plurality of
bricks comprises an oblique top section and an oblique bottom section, wherein
each of the
oblique top and bottom sections protrude from the face of the frame and
preferably the
oblique top and bottom sections of each brick are substantially parallel to
each other.
[0042] In accordance with yet another aspect of the frame/brick construction
of the present
invention, the plurality of bricks at least partially disposed in the
plurality of channels form a
plurality of stacked, substantially horizontal rows of bricks protruding from
the front face of
the frame; and wherein the oblique top section of one brick is disposed
substantially near,
adjacent to, in partial contact with or in complete contact with the oblique
bottom section of
another brick immediately above the one brick.
[0043] In yet another aspect, the present invention comprises a method for
assembling a
stave/brick construction comprising: providing a stave in a standing position,
wherein the
stave has a plurality of ribs and a plurality of channels, wherein a front
face of the stave
defmes a first opening into each of the channels; and inserting a plurality of
bricks into each
channel via its first opening so that a first portion of each brick enters its
respective channel
via its first opening; and rotating each brick so that it is partially
disposed in its respective
channel with its first portion at least partially engaged with one or more
surfaces of its
respective channel and/or of a first rib of the plurality of stave ribs
whereby the brick is
locked against linear movement out of the one channel through its first
opening. Preferably,
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after inserting, the first portion of each brick is at least partially
disposed in a first section of
its respective channel, and the rotating of each brick comprises a bottom of
the brick moving
in a direction towards the stave.
[0044] In accordance with yet another aspect, the method for assembling a
stave/brick
construction of the present invention further comprises: removing one or more
of the plurality
of bricks from their respective channels via rotation of the one or more
bricks comprising a
bottom of each brick moving in a direction away from the stave.
[0045] In yet another aspect, the present invention comprises a brick for a
stave/brick
construction, comprising: a top section defining a nose contiguous with a
locking side of the
brick and an upper oblique section contiguous with a first face of the brick,
wherein the
locking side comprises the nose, a second face, a seat and a lower concave
section; and a
bottom defining a lower oblique section contiguous with the first face of the
brick. Preferably,
brick may further comprise a groove defined by the top section disposed across
a width of the
brick.
[0046] In accordance with yet another aspect, the brick for a stave/brick
construction of the
present invention, the second face extends from the nose to the seat and is
opposite to the first
face. Also, preferably, a height of the second face is equal to or greater
than about two times a
depth of the brick measured from the second face to a bottom of the groove.
[0047] In accordance with yet a farther aspect of the brick for a stave/brick
construction of
the present invention, preferably one or both of the nose and seat may be
arcuate, polygonal
or angular. Also, one or both of the first and second faces of the brick
preferably are
substantially flat.
[0048] In yet another aspect, the present invention comprises a stave/brick
construction,
comprising: a stave having a plurality of ribs and a plurality of channels,
wherein a front face
of the stave defines a first opening into each of the channels and wherein the
plurality of ribs
comprises one or more short ribs each of which is shorter than one or more
adjacent long ribs,
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wherein each short rib and at least one adjacent long rib define, at least in
part, a void such
that the stave defines a plurality of voids; and a plurality of bricks wherein
each brick is
insertable into one of the plurality of voids in a direction substantially
perpendicular to the
front face to a first position from which it can be slid to a second position
within one of the
plurality of channels.
[0049] Many other variations are possible with the present invention, and
those and other
teachings, variations, and advantages of the present invention will become
apparent from the
description and figures of the invention.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0050] For the present disclosure to be easily understood and readily
practiced, the present
disclosure will now be described for purposes of illustration and not
limitation in connection
with the following figures, wherein:
[0051] FIG. 1 is a front perspective view of a conventional stave;
[0052] FIG. 2 is a side perspective view of a conventional, dove-tailed
refractory brick;
[0053] FIG. 3 is a side perspective view of a brick according to a preferred
embodiment of
the present invention;
[0054] FIG. 4 is a top perspective view of a preferred embodiment of a furnace
lining of the
present invention comprising a preferred embodiment of a stave/brick
construction of the
present invention employing the brick of FIG. 3;
[0055] FIG. 5 is a side perspective view of a preferred embodiment of a
furnace lining of the
present invention comprising a preferred embodiment of a stave/brick
construction of the
present invention employing the brick of FIG. 3;
[0056] FIG. 6 is a cross-sectional view of a preferred embodiment of a
stave/brick
construction of the present invention employing the brick of FIG. 3;
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[0057] FIG. 7 is a cross-sectional view of a preferred embodiment of a
stave/brick
construction of the present invention showing the brick of FIG. 3 as it is
being inserted or
removed from a front face of a preferred embodiment of a stave of the present
invention;
[0058] FIG. 8 is a cross-sectional view of a preferred embodiment of an
alternative
stave/brick construction of the present invention employing at least two
different sizes of the
bricks of FIG. 3.
[0059] FIG. 9 is a top plan view of a conventional furnace lining employing
conventional
stave/brick constructions;
[0060] FIG. 10 is a top plan view of a preferred embodiment of a furnace
lining of the
present invention comprising a preferred embodiment of a stave/brick
construction of the
present invention employing the brick of FIG. 3;
[0061] FIG. 11 is a cross-sectional view of another preferred embodiment of a
stave/brick
construction of the present invention; and
[0062] FIG. 12 is a partial, front elevational view of the stave/brick
construction of FIG. 11.
DETAILED DESCRIPTION OF PREFERRED
EMBODIMENT(S) OF THE INVENTION
[0063] In the following detailed description, reference is made to the
accompanying
examples and figures that form a part hereof, and in which is shown, by way of
illustration,
specific embodiments in which the inventive subject matter may be practiced.
These
embodiments are described in sufficient detail to enable those skilled in the
art to practice
them, and it is to be understood that other embodiments may be utilized and
that structural or
logical changes may be made without departing from the scope of the inventive
subject
matter. Such embodiments of the inventive subject matter may be referred to,
individually
and/or collectively, herein by the term "invention" merely for convenience and
without
intending to voluntarily limit the scope of this application to any single
invention or inventive
concept if more than one is in fact disclosed.
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[0064] The following description is, therefore, not to be taken in a limited
sense, and the
scope of the inventive subject matter is defmed by the appended claims and
their equivalents.
[0065] FIG. 1 illustrates a planar, fluid cooled stave 10 of known
construction having a
plurality of stave ribs 11 and defining a plurality of stave channels 12, both
of generally
rectangular cross-sections for use with bricks having matching cross-sections.
Other stave
designs of known construction (not shown) employ stave ribs and stave channels
having
cross-sections complementary to the dovetail sections 16 of the conventional
refractory brick
14 shown in FIG. 2 to allow such dovetailed sections 16 thereof to be inserted
into the side
ends of the stave and slid into position therein with or without mortar in
between each
adjacent brick. A major disadvantage of such known stave/brick constructions
is that due to
the closeness to each other when installed in a furnace, such staves 10 must
be removed from
the furnace to allow the bricks 14 to be slid out of the stave channels 12
whenever the
stave/brick construction needs to be rebuilt or repaired, either in-whole or
in-part. Removing
such staves 10 from the furnace is necessitated because bricks 14 cannot be
removed or
inserted into stave channels 12 through the front face of stave 10. As shown
in FIG. 1, stave
comprises a plurality of pipes 13 disposed inside the stave 10 which may be
connected to
one or more external pipes that extend from the furnace shell side of the
stave 10 and
penetrate the metal shell of the furnace so that coolant, such as, for
example, water at an
elevated pressure is pumped through the pipes 13 in order to cool the stave 10
and any
refractory bricks disposed within stave channels 12 when assembled and
installed in a
furnace.
[0066] As further illustrated in FIG. 2, conventional dovetailed refractory
brick 14 has a
relatively thin vertical neck 15 which is susceptible to breakage in the
furnace environment,
particularly where the length of protruding portion 17 of brick 14 which
protrudes into the
furnace from stave 10 is long relative to the overall depth or length of brick
14.
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[0067] FIG. 3 illustrates a preferred embodiment of a refractory brick 18
according to a
preferred embodiment of a stave/brick construction 28 of the present
invention. Brick 18 has
an exposed face 26 and oblique or slanted top and bottom sections 19 and 20,
respectively.
Brick 18 also comprises or defines a locking side 29 comprising concave groove
22, a
generally arcuate nose 23, a generally arcuate seat 25, a generally arcuate
concave section 24,
a lower face 27 and a generally planar front face 31. Brick 18 also has a neck
21, the vertical
thickness ("ab") of which is increased with respect to the vertical neck 15 of
known bricks 14.
Preferably, the length "ab" of vertical neck 21 is equal to or greater than
about two (2) times
the length "cd" of the depth of brick 18 that is disposed in stave channel 37
when the brick 18
is installed therein. The shapes, geometries and/or cross-sections of brick 18
and/or any part
thereof, including, without limitation, one or more of exposed face 26, lower
face 27, front
face 31, oblique/slanted top section 19, oblique/slanted bottom section 20,
groove 22, nose
23, seat 25, concave section 24 and front locking side 29 may be modified or
take other forms
such as being angular, rectilinear, polygonal, geared, toothed, symmetrical,
asymmetrical or
irregular instead the shapes of the preferred embodiments thereof as shown in
the drawings
hereof without departing from the scope of the invention hereof. The
refractory bricks 18 of
the present invention preferably may be constructed from many of the
refractory materials
currently available including, but not limited to, silicon carbide (such as
Sicanit AL3 available
from Saint-Gobain Ceramics), MgO-C (magnesia carbon), alumina, insulating fire
brick
(IFB), graphite refractory brick and carbon. In addition, bricks 18 may be
constructed from
alternating or different materials depending upon their location in a stave 30
or within the
furnace. Also, as set forth above, the shape of bricks 18 may also be modified
or altered to
meet various stave and/or furnace spaces and/or geometries.
[0068] Preferred embodiments of a stave/refractory brick construction 28 of
the present
invention is shown in FIGS. 3-8 and 10, including a preferred embodiment of a
stave 30 of
the present invention. Stave 30 may comprise a plurality of pipes (not shown),
such as the
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pipes 13 disposed inside the stave 10 as shown in FIG. 1, which may be
attached to one or
more external pipes that extend from the furnace shell side of the stave 30
and penetrate the
metal shell of the furnace so that coolant, such as, for example, water at an
elevated pressure
is pumped through such pipes (not shown) in order to cool the stave 30 and any
refractory
bricks 18 disposed within stave channels 37 thereof when assembled and
installed in a
furnace. Preferably, the stave 30 is constructed of copper, cast iron or other
metal of high
thermal conductivity, while any pipes disposed with stave 30 are preferably
made from steel.
100691 Each stave 30 preferably may be curved about its horizontal axis and/or
about its
vertical axis to match the internal profile of the furnace or area in which
they will be used.
Each stave 30 preferably comprises a plurality of stave ribs 32 and a stave
socle 33 to support
stave 30 in a standing position which may be a fully upright 90 degrees as
shown, or a tilted
or slanted position (not shown). Each stave rib 32 preferably defines a
generally arcuate top
rib section 34 and a generally arcuate bottom rib section 35. Stave 30
preferably defines a
plurality stave channels 37 between each successive pair of stave ribs 32.
Preferably, each
stave channel 37 is generally "C-shaped" or "U-shaped" and includes a
generally planar stave
channel wall 38, although stave channel wall 38 may also be curved or
contoured along its
vertical and/or horizontal axes, toothed, etc., to be complementary with the
front face 31 of
brick 18 if such front face 31 has a shape other than the planar shape
depicted herein, which
may depend upon the application. Each stave channel 37 also preferably
includes a generally
arcuate upper channel section 39 and a generally arcuate lower channel section
40, all as
defmed by stave 30 and a successive pair of stave ribs 32. The shapes,
geometries and/or
cross-sections of one or more of the stave ribs 32, top rib sections 34,
bottom rib sections 35,
stave channels 37, stave channel walls 38, upper channel sections 39 and lower
channel
sections 40, preferably may be modified or take other forms such as being
contoured, angular,
rectilinear, polygonal, geared, toothed, symmetrical, asymmetrical or
irregular instead the
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shapes of the preferred embodiments thereof as shown in the drawings hereof
without
departing from the scope of the invention hereof.
[0070] As shown in FIGS. 6 and 7, while the stave bricks 18 of the present
invention may be
slid into stave channels 37 from the sides 45 of stave 30 when space permits,
stave bricks 18
may also preferably and advantageously be inserted into the front face 47 of
staves 30.
Beginning at the bottom of stave 30, each stave channel 37 may be filled with
stave bricks 18
by rotating or tilting each brick 18 in a first direction 46 where the bottom
portion of brick 18
moves away from stave 30 preferably (1) about an axis substantially parallel a
plane of the
stave or (2) to allow nose 23 to be inserted into stave channel 37 and into
concave, arcuate
upper channel section 39, after which brick 18 is rotated in a second
direction 48 generally
such that the bottom of brick 18 moves toward stave 30 until (i) nose 23 is
disposed in-whole
or in-part within concave, arcuate upper channel section 39 with or without
the perimeter of
nose 23 being in partial or complete contact with upper channel section 39,
(ii) front face 31
of brick 18 is disposed substantially near and/or adjacent to channel wall 38
with or without
the front face 31 being in partial or complete contact with channel wall 38,
(iii) arcuate seat
25 is disposed in-whole or in-part within arcuate lower channel section 40
with or without the
perimeter of seat 25 being in partial or complete contact with lower channel
section 40, (iv)
arcuate concave section 24 is disposed in-whole or in-part over the arcuate
top rib section 34
of the lower stave rib 32 of the successive pair of stave ribs 32 defming the
stave channel 37
into which the brick 18 is being inserted with or without the inside surface
of concave section
24 being in partial or complete contact with the arcuate top rib section 34 of
such lower stave
rib 32, (v) lower face 27 of brick 18 is disposed substantially near and/or
adjacent to rib face
36 with or without the lower face 27 being in partial or complete contact with
rib face 36,
and/or (vi) slanted bottom section 20 of the brick 18 being installed is
disposed substantially
near and/or adjacent to slanted top section 19 of the brick 18 immediately
below the brick 18
being installed with or without such slanted bottom section 20 being in
partial or complete
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contact with such slanted top section 19, in the case where the brick 18 is
being installed in
any of the stave channels 37 except the lowest stave channel 37 of stave 30.
As illustrated in
FIGS. 5-7, when the nose 23 is disposed in-whole or in-part within concave,
arcuate upper
channel section 39 with or without the perimeter of nose 23 being in partial
or complete
contact with concave, upper channel section 39, and/or arcuate seat 25 is
disposed in-whole or
in-part within concave, arcuate lower channel section 40 with or without the
perimeter of seat
25 being in partial or complete contact with concave, lower channel section
40, each of the
bricks 18 is prevented from being moved linearly out of stave channel 37
through the opening
in the front face 47 of stave 30 without each brick 18 being rotated such that
the bottom
thereof is rotated away from the front face 47 of stave 30.
[0071] As also shown in FIGS. 5-8, once a row of bricks 18 is installed in a
stave channel 37
above a row of previously installed bricks 18, the bricks 18 in such
immediately lower row
are locked into place and cannot be rotated in the first direction 46 away
from stave 30 to be
removed from stave channel 37. The stave/refractory brick construction 28 of
the present
invention as shown in FIGS. 3-7 and 10 may be employed with or without mortar
between
adjacent stave bricks 18.
[0072] FIG. 8 illustrates another preferred embodiment of a stave/brick
construction 90 of
the present invention which is the same as stave/ brick construction 28 of
FIGS. 4-7 except
that it employs at least two different sizes of stave bricks 92 and 94,
respectively, to form an
uneven front face 96. As shown, bricks 92 of the stave/brick construction 90
have a greater
overall depth "cel" than the depth "ce2" of bricks 94. This staggered
construction resulting
from the different depths of stave bricks 92 and 94, respectively, may
preferably be used in
accretion zones or other desirable zones of the furnace where the uneven front
face 96 would
be more effective at holding an accretion or buildup of material to further
protect the bricks
92 and 94 from thermal and/or mechanical damage.
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[0073] FIG. 9 illustrates the use of conventional stave/brick constructions 58
within a
furnace 49. When using flat or curved staves/coolers, such as the flat/planar
upper and lower
staves 52 and 53, respectively, with pre-installed bricks 54 arranged within
furnace shell 51,
such staves 52 and 53 are installed in the furnace 49 such that ram gaps 56
exist in between
adjacent pairs of upper staves 52 and such that ram gaps 57 exist in between
adjacent pairs of
lower staves 53, both to allow for construction allowance. These ram gaps 56
and 57 must
be used to allow for construction deviation. Such ram gaps 56 and 57 are
typically rammed
with refractory material (not shown) to close such gaps 56 and 57 between the
adjacent
stave/brick constructions 58. Such material filled gaps 56 and 57 typically
are weak points in
such conventional furnace linings using stave/brick constructions 58. During
operation of
furnace 49, the rammed gaps 56 and 57 erode prematurely and furnace gases
track between
the stave/brick constructions 58. With the preferably curved stave/brick
constructions 28 of
the present invention, the furnace can be bricked continuously around its
circumference to
eliminate conventional rammed gaps with bricks 18. As shown in FIG. 10, the
gaps 42
between staves 30 are covered by one or more of bricks 18 of the present
invention,
eliminating the need for ramming filling material into such gaps 42. By
eliminating the
conventional rammed gaps 56 and 57 between the furnace bricks of adjacent
staves 30, the
integrity and life of the furnace and/or furnace lining is increased.
[0074] Another problem associated with the conventional stave/brick
constructions 58
having pre-installed bricks 54, as shown in FIG. 9, is that because such
conventional
stave/brick constructions 58 are not continuously bricked around the
circumference of furnace
49, edges 55 of numerous of the bricks 54 protrude into the interior of
furnace 49 and are thus
exposed to any matter falling through the furnace 49. Such protruding edges 55
tend to wear
faster and/or are susceptible to being hit by falling matter, causing such
bricks 54 with
protruding edges 55 to break off into the furnace 49 and expose the staves 52
and 53. Again,
the stave/brick constructions 28 of the present invention allow the furnace to
be bricked
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continuously around its circumference thereby eliminating any such protruding
brick edges
55, as shown in FIG. 10. Thus, the occurrences of (i) bricks 18 being pulled
or knocked out
of staves 30 and (ii) of staves 30 being directly exposed to the intense heat
of the furnace are
both significantly reduced by the stave/brick construction 28 of the present
invention. Such
characteristics make the stave/brick construction 28 of the present invention
well-suited for
use in the stack of blast furnaces.
[0075] As also shown in FIG. 10, a plurality of pin mounting cylinders 43 are
preferably
formed on the back side of each stave 30 for mounting pins 41 used to handle
each stave 30,
and/or to secure and/or mount each stave 30 within a furnace. Each of the pins
41 preferably
defines a threaded or unthreaded thermocouple mounting hole (not shown)
allowing one or
more thermocouples to be easily installed at various locations on each stave
30.
[0076] While the preferred embodiment of a stave/refractory brick construction
28 of the
present invention shown in FIGS. 3-8 and 10, includes a preferred embodiment
of a furnace
cooler or stave 30, the teachings of the present invention are also applicable
to a frame/brick
construction where such frame (not shown) is not limited to a furnace cooler
or stave 30, but
is a frame for providing a standing or other supported vertical or slanted
wall of bricks,
whether or not refractory bricks, for applications including, but not limited
to, furnace
applications.
[0077] FIGS 11-12 illustrate another preferred embodiment of a stave/brick
construction 59
of the present invention comprising stave 60 and alternating shallow and deep
dovetail bricks
68 and 69, respectively, including top line stave brick 67 which preferably
has the same depth
as a long brick 69 and an exposed face 75 of greater height than the exposed
faces 76 of the
other shallow and deep dovetail bricks 68 and 69. As shown, both shallow and
deep dovetail
bricks 68 and 69 have upper and lower dovetail or oblique sections 73 and 74,
respectively.
Further, each of the bricks 67, 68 and 69 defines two brick comers 71 while
deep bricks 69
define two concave brick vertexes 70 that match up with the brick corners 71
of shallow
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bricks 68 upon completion of the stave/brick construction 59 of the present
invention. Stave
60 preferably comprises a plurality of stave ribs 64 and a stave socle (not
shown) to support
stave 60 in a standing position which may be a fully upright 90 degrees, or a
tilted or slanted
position. Each stave rib 64 preferably defines generally angular upper and
lower rib edges 65
and 66, respectively. Stave 60 preferably defines a plurality stave channels
61 between each
successive pair of stave ribs 64. Preferably, each stave channel 61 comprises
a generally
planar stave channel wall 77, although stave channel wall 77 may also be
curved or contoured
along its vertical and/or horizontal axes, toothed, etc., to be complementary
with the front
faces 78 of the deep dovetail bricks 69 if such front face 78 has a shape
other than the planar
shape depicted herein, which may depend upon the application. Each stave
channel 61 also
preferably includes a generally dovetail-shaped upper channel section 62 and a
generally
dovetail-shaped lower channel section 63, all as defined by stave 60 and a
successive pair of
stave ribs 64. The shapes, geometries and/or cross-sections of one or more of
the stave ribs
64, upper and lower rib edges 65 and 66, stave channels 61, stave channel
walls 77, upper
channel sections 62, lower channel sections 63, brick vertexes 70 and brick
edges 71, upper
and lower dovetail sections 73 and 74, exposed faces 75 and 76 and front faces
78 preferably
may be modified or take other forms such as being contoured, angular,
rectilinear, polygonal,
geared, toothed, symmetrical, asymmetrical or irregular instead the shapes of
the preferred
embodiments thereof as shown in the drawings hereof with out departing from
the scope of
the present invention.
[0078] The view of stave/brick construction 59 of the present invention in
FIG. 12 shows
that every other one 79 of stave ribs 64 is preferably shortened by less than
half the thickness
(i.e., width) of bricks 67, 68 and 69, that is by: ((brick thickness -
designed gap length
between the staves or coolers)/2) + 1/4" for construction deviation. An
additional brick (not
shown), preferably of higher thermal conductivity to promote cooling similar
to that of the
stave/cooler 60, would be installed in place of the missing section of stave
rib 64 to fill the
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void 80. Such stave/brick construction 59 allows the bricks 67, 68 and 69 to
be inserted into
and/or removed from stave channels 61, after stave 60 has been installed in
the furnace, by
sliding such bricks into stave channels 61 via voids 80, i.e., the extra room
created by
shortened stave ribs 79.
[00791 The stave/brick construction 59 may preferably employ a single brick
design (not
shown) or the alternating shallow and deep bricks 68 and 69, respectively, as
shown in FIG.
11 wherein the dovetail sections 73 and 74 of deep bricks 69 are inserted and
received into
stave channels 61, each of the front faces 78 of shallow bricks 68 is disposed
substantially
near and/or adjacent to a respective face 81 of a stave rib 64 with or without
such front face 78
being in partial or complete contact with its respective rib face 81, and each
of the brick edges
71 of shallow bricks 68 is disposed substantially near and/or adjacent to a
respective vertex 70
of a deep brick 69 with or without such brick edge 71 being in partial or
complete contact with
its respective vertex 70 of a deep brick 69. Additionally, other stave/brick
constructions
employing bricks of two or more different shapes with a portion of all such
bricks being
received in a stave channel is within the scope of the present invention.
[0080] The stave/brick constructions of the present invention preferably also
may be
assembled initially by setting the bricks in a form and casting the stave
around the bricks.
[0081] In the foregoing Detailed Description, various features are grouped
together in a
single embodiment to streamline the disclosure. This method of disclosure is
not to be
interpreted as reflecting an intention that the claimed embodiments of the
invention require
more features than are expressly recited in each claim. Rather, as the
following claims reflect,
inventive subject matter lies in less than all features of a single disclosed
embodiment.
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